Apparatus and related methods for preparing popcorn

ABSTRACT

A heated air popcorn popper provides easy access and clean up through the use of a detachable popping pitcher. The detachable popping pitcher defines an interior popping volume in which heated air is used to cause unpopped kernels to pop and form popped popcorn. The detachable popping pitcher includes a pitcher handle allowing a user to grasp and manipulate the popping pitcher when selectively detaching and attaching the popping pitcher to the popcorn popper. The detachable popping pitcher is completely removable from a popper housing such that loading unpopped kernels into the popping pitcher is simplified and the user need not be concerned about access being awkward or limited. The detachable popping pitcher can be fully removed from the popper housing following popping such that any remaining unpopped or popped kernels can be emptied from the detachable popping pitcher and the detachable popping pitcher can be cleaned.

FIELD OF THE INVENTION

The present invention relates generally to apparatus and methods forpreparing popcorn. More specifically, the present invention relates toapparatus and related methods of preparing popcorn using a hot airpopper with a removable kernel pitcher.

BACKGROUND OF THE INVENTION

Popcorn is one of the most universally consumed snacks. Conventionalmethods for preparing popcorn have utilized heated oil, microwaveheating or heated air as the heating medium. One benefit of utilizingheated air is that the user can control the addition of any extracalories or fat as no oil is utilized in the popping process.Additionally, butter and/or other flavors or toppings can be added, ifdesired, after the popping process is completed.

One of the most popular settings for the consumption of popcorn is inmovie theaters. Traditionally, theaters have utilized heated oil basedsystems to pop large volumes of popcorn. During the popping process,popped kernels exit out of a popping tub and are collected on the floorof a popping structure that allows for theater workers to reach in andfill bags or tubs with freshly popped popcorn. Following popping, thetheater workers typically rotate the popping tub to an upside downdisposition so that any remaining popped and unpopped kernels areemptied onto the floor of the popping structure.

The look and style of traditional theater popcorn poppers has beenreplicated in a smaller fashion so as to fit into a home setting.Generally, these home versions of the theater popcorn popper have areduced size such that smaller volumes of popcorn are popped and storedfor consumption. In addition to having a reduced size, the way in whichkernels are popped have been changed from a conventional heated oilarrangement to a hot air arrangement. Using heated air allows forcleaner operation and does not require the user to have oil on hand. Inaddition, the heated air operation reduces the potential for smoke.

While theater style popcorn poppers are available for residential use,it would be advantageous to further improve upon their designs toprovide additional functionality and ease of use.

SUMMARY OF THE INVENTION

A heated air popcorn popper of the present invention provides easyaccess and clean up through the use of a detachable popping pitcher.Generally, the detachable popping pitcher defines an interior poppingvolume in which heated air is used to cause unpopped kernels to pop andform popped popcorn. The detachable popping pitcher can comprise apitcher handle allowing a user to grasp and manipulate the poppingpitcher when selectively detaching and attaching the popping pitcher tothe popcorn popper. In a theater style, heated air popcorn popper, thedetachable popping pitcher is completely removable from a popper housingsuch that loading unpopped kernels into the popping pitcher issimplified and the user need not be concerned about access being awkwardor limited. In a similar manner, the detachable popping pitcher can befully removed from the popper housing following popping such that anyremaining unpopped or popped kernels can be emptied from the detachablepopping pitcher and the detachable popping pitcher can be cleaned if sodesired. In some embodiments, the detachable popping pitcher can beselectively detached or attached from the popcorn popper with a latchingmechanism. In some embodiments, the detachable popping pitcher caninclude one or more retaining members at an upper portion of the poppingpitcher to retain popcorn in a popping volume of the popping pitcheruntil the level of popcorn rises so as to physically cause the one ormore retaining members to open.

In one aspect, the present invention is directed to a popcorn popperhaving a detachable popping pitcher.

In another aspect, the present invention is directed to a method forloading unpopped kernels into a popcorn popper.

In yet another aspect, the present invention can comprise atheater-style hot air popper having a detachable popping pitcher forloading unpopped kernels outside of the theater-style hot air popper.

In yet another aspect, the present invention is directed to a method ofemptying a popcorn popper by removing a detachable popping pitcher. Insome embodiments, the method can further comprise cleaning thedetachable popping pitcher.

The above summary of the various representative embodiments of theinvention is not intended to describe each illustrated embodiment orevery implementation of the invention. Rather, the embodiments arechosen and described so that others skilled in the art can appreciateand understand the principles and practices of the invention. Thefigures in the detailed description that follow more particularlyexemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

A specific embodiment is now described by way of example to further theunderstanding of the present disclosure, with reference to theaccompanying drawings in which:

FIG. 1 is a front view of a theater-style popcorn popper according to arepresentative embodiment of the present invention.

FIG. 2 is a side view of the theater-style popcorn popper of FIG. 1.

FIG. 3 is a rear view of the theater-style popcorn popper of FIG. 1.

FIG. 4 is a side view of the theater-style popcorn popper of FIG. 1.

FIG. 5 is a bottom view of the theater-style popcorn popper of FIG. 1.

FIG. 6 is a top view of the theater-style popcorn popper of FIG. 1.

FIG. 7 is a top, perspective view of the theater-style popcorn popper ofFIG. 1.

FIG. 8 is a top, perspective view of the theater-style popcorn popper ofFIG. 1 with a door in an open position and a detachable popping pitcherremoved from a popper housing.

FIG. 9 is a front view of a detachable popping pitcher according to arepresentative embodiment of the present invention.

FIG. 10 is a side view of the detachable popping pitcher of FIG. 9.

FIG. 11 is a rear view of the detachable popping pitcher of FIG. 9.

FIG. 12 is a side view of the detachable popping pitcher of FIG. 9.

FIG. 13 is a top view of the detachable popping pitcher of FIG. 9.

FIG. 14 is a bottom view of the detachable popping pitcher of FIG. 9.

FIG. 15 is a top, perspective view of the detachable popping pitcher ofFIG. 9.

FIG. 16 is a top, perspective view of the detachable popping pitcher ofFIG. 9 having a plurality of retention members in an open disposition.

FIG. 17 is a bottom, perspective view of the detachable popping pitcherof FIG. 9.

FIG. 18 is a partial section view of the theater-style popcorn popper ofFIG. 1.

FIG. 19 is a partial section view of the theater-style popcorn popper ofFIG. 1 illustrating the detachable popping pitcher being separated froma mounting surface in the popper housing.

FIG. 20 is a top, perspective view of the detachable popping pitcher ofFIG. 9.

FIG. 21 is a front, perspective view of the theater-style popcorn popperof FIG. 1 with the detachable popping pitcher being removed from thepopper housing.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example in thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring generally to FIGS. 1-8, a representative embodiment of apopcorn popper 100 of the present invention can comprise a popperhousing 102 and a detachable popping pitcher 104. In some embodiments,popper housing 102 can comprise a theater-style housing 106. Inaddition, popcorn popper 100 can also include one or more servingbaskets 108. Popcorn popper 100 is generally fabricated of materialssuited for food contact and preparation including metals such asaluminum and stainless steel, plastic polymers such as polycarbonate,glass as well as similar materials and combinations thereof.

With reference to FIGS. 1-8, popper housing 102 generally includes apair of side walls 110 a, 110 b, a rear wall 112, a front wall 114, atop wall 116 and a base assembly 118. Front wall 114 is generallydefined by a door assembly 120 and a serving panel 122. Door assembly120 generally comprises a transparent door 124, a door handle 126 anddoor hinge assemblies 128 a, 128 b. The base assembly 118 can define acontrol surface 130 including a control or power button 132 for operablycontrolling the popcorn popper 100 as well as a removable tray 134. Thebase assembly 118 further defines an interior floor surface 136 as wellas an external bottom surface 138. Top wall 116 can comprise a trayrecess 140 and an air vent 142. Each of the side walls 110 a, 110 bgenerally comprises a transparent surface 144 having a vent portion 146.

Within an interior portion 150 of the popper housing 102, the baseassembly 118 defines a mounting platform 152 as illustrated in FIGS. 8,18 and 19. Mounting platform 152 can comprise a mounting surface 154that is supported by an elevated mounting wall 156. Mounting surface 154can comprise an airflow screen 158. The mounting surface 154 can furtherinclude a latch receiver 160 oriented toward the front wall 114.Mounting surface 154 and rear wall 112 can cooperatively define apositioning recess 162. Mounting platform 152 generally defines aninterior mounting area 164, which can accommodate a fan assembly 166 anda heating member 168. Fan assembly 166 can generally comprise a fanwheel 170 and motor 172 while heating member 168 can comprise aresistive heating element 174. Interior mounting area 164 is generallyopen to an interior base portion 176 that can accommodate controls,wiring and other electrical and safety necessities.

As shown in FIGS. 9-17, detachable popping pitcher 104 generallycomprises a pitcher body 180 defined by a pitcher wall 182, an upperpitcher opening 184, a pitcher floor 186 and an interior heating zone188. Pitcher body 180 can have a generally circular cross-section asillustrated or alternatively, the pitcher body 180 can have across-sectional shape selected from squares, rectangles, triangles andcombinations thereof. Generally, the cross-section of pitcher body 180will substantially resemble a cross-section of the mounting platform 152to promote positioning and attachment of the pitcher body 180 relativeto the mounting platform 152. Pitcher floor 186 generally includes apitcher screen 190 formed of a mesh or screen material having aperturessignificantly reduced in size compared to individual popcorn kernels.Pitcher floor 186 can further define a positioning tab 191. Pitcher body180 can further comprise a kernel retention mechanism 192 or means forretaining at the upper pitcher opening 184.

In a representative embodiment, kernel retention mechanism 192 cancomprise one or more lid members 194 that are attached to the upperpitcher opening 184 with a corresponding hinge assembly 196. Lid member194 can comprise two or more lid members 194, such as, for example,three lid members 194 as illustrated with the only requirement beingthat in combination, the lid members 194 cover the entire upper pitcheropening 184. Each lid member 194 includes a plurality of lid ventopenings 198. Each lid member 194 has a corresponding hinge assemblymember 196 such that the lid members 194 are individually capable oftransitioning between a covering disposition 200 as seen in FIGS. 7, 8,13 and 15 and an open disposition 202 as seen in FIGS. 16, 20 and 21.

Attached to the pitcher body 180 is a pitcher handle 204. Proximate thepitcher floor 186, the pitcher handle 204 can define a latch member 206having a tapered latch surface 207 as seen in FIGS. 18 and 19. Pitcherhandle 204 can further comprise a latch actuator 208 that is operablyinterconnected to the latch member 206 such that depression of the latchactuator 208 changes the position of the latch member 206.

In order to use popcorn popper 100, popping pitcher 104 must be filledwith unpopped kernels 210 as illustrated in FIG. 20. Generally, poppingpitcher 104 is positioned outside of the popper housing 102 to provideeasy access to the upper pitcher opening 184. If popping pitcher 104includes kernel retention mechanism 192, the kernel retention mechanismis first directed to the open disposition 202 so as provide unimpededaccess to the interior heating zone 188 through upper pitcher opening184. As the unpopped kernels 210 are poured into the interior heatingzone 188, they accumulate on the pitcher floor 186 and are retained bythe pitcher screen 190. Once the desired amount of the unpopped kernels210 are poured into the popping pitcher 104, the kernel retentionmechanism 192 can be directed to the covering disposition 200 tomaintain the unpopped kernels 210 within the interior heating zone 188.

With the popping pitcher 104 filled with the desired amount of unpoppedkernels 210, the user opens the transparent door 124 to allow accessinto the interior portion 150 of the popper housing 102. The userdirects the popping pitcher 104 proximate the mounting platform 152 andbegins to engage the mounting platform 152 by guiding the positioningtab 191 into the positioning recess 162 as shown in FIG. 19. With thepositioning tab 191 positioned in the positioning recess 192, the usercan lower the popping pitcher 104 such that the pitcher floor 186 setsonto the mounting surface 154. When the pitcher floor 186 is flush withthe mounting surface 154, the tapered latch surface 207 causes the latchmember 206 to slip past the latch receiver 160, such that the latchmember 206 and latch receiver 160 in conjunction with the interaction ofthe positioning tab 191 and positioning recess 162, maintain theattachment and alignment of the popping pitcher 104 relative to themounting platform 152 as shown in FIG. 18. With the popping pitcher 104attached to the mounting platform 152, the airflow screen 158 and thepitcher screen 190 are aligned so as to allow airflow from the interiormounting area 164 into the interior heating zone 188.

With the popcorn popper 100 assembled through attachment of the poppingpitcher 104 to the mounting platform 152, the user can plug in anelectrical cord (not shown) and utilize the control button 132 to begina popping cycle. Generally, the fan assembly 166 directs air through theheating member 168 and into the popping pitcher 104 through the alignedairflow screen 158 and pitcher screen 190 whereby the heated airinteracts with the unpopped kernels 210 within the interior heating zone188. Generally, the unpopped kernels 210 are agitated by the heated airand can even be carried upward by the heated air. If unpopped kernels210 are carried upward, the eventually contact the kernel retentionmechanism 192 which prevents the unpopped kernels 210 from exiting theinterior heating zone 188. After a period of time, the unpopped kernels210 begin reaching an internal temperature of at least 185° F., wherebymoisture within the unpopped kernels 210 is converted to steam, thuscausing the unpopped kernels 210 to “pop” and become a popped kernel212. Each popped kernel 212 is substantially larger in physical volumefollowing popping, thereby causing the internal heating zone 188 tobecome filled with popped kernels 212. As the popped kernels 212accumulate and stack upon one another, eventually an upper level of thepopped kernels 212 reaches the kernel retention mechanism 192. As theupper level of the popped kernels 212 contacts the kernel retentionmechanism 192, the kernel retention mechanism 192 is physically forcedupward and caused to transition from the covering disposition 200 to theopen disposition 202, for example, by causing each lid member 194 toflip from the covering disposition 200 to the open disposition 202. Asthe kernel retention mechanism 192 transitions to the open disposition202, the heated air blows upward through the upper pitcher opening 184such that the popped kernels 212 begin exiting the internal heating zone188 and begin to accumulate on the interior floor surface 136 of thebase assembly 118.

After a period of time, the unpopped kernels 210 have “popped” andbecome popped kernels 212. At that point, the popping cycle is completedand the fan assembly 166 and heating member 168 are deenergized orturned off. At this point, the majority of popped kernels 212 havelikely exited the popping pitcher 104 and reside on the interior floorsurface 136. The user can open the door assembly 120 and grasp thepitcher handle 204. As the user grasps the pitcher handle, the latchactuator 208 can be depressed thereby causing the latch member 206 toretract away from the latch receiver 160. The user can then beginlifting the popping pitcher 104 away from the mounting platform 152 suchthat the positioning tab 191 is removed from the positioning recess 162.With the popping pitcher 104 fully detached from the mounting platform152, the user can orient the popping pitcher 104 in an upside downorientation to empty any remaining popped kernels 212 from the interiorheating zone 188 as shown in FIG. 21. The user can then remove thepopping pitcher 104 from the popper housing 102, whereby the poppingpitcher 104 can be reloaded with unpopped kernels 210 or alternatively,the popping pitcher 104 can be cleaned.

While a specific embodiment has been described above by way ofillustration, it will be appreciated that the described principles areequally applicable to a wide range of popcorn popper products andconfigurations. More generally, numerous adaptations, modifications,combinations and juxtapositions of the features described above may bemade without departing from the principles of the presently disclosedinvention.

The invention claimed is:
 1. A popcorn popper, comprising: a popperhousing defining an interior portion having a mounting surface, thepopper housing having a rear wall and wherein the rear wall and themounting surface define a positioning recess; and a detachable poppingpitcher, the detachable popping pitcher defining an internal heatingzone for receiving popcorn kernels, the detachable popping pitcherincluding a latch member for selectively coupling the detachable poppingpitcher to the mounting surface during popping of the popcorn kernel,the detachable popping pitcher further including a positioning tabproximate a lower pitcher surface, wherein the detachable poppingpitcher is selectively detached from the mounting surface and removedfrom the interior portion during loading of the popcorn kernels into theinternal heating zone; and wherein the positioning tab is insertableinto the positioning recess to guide attachment of the detachablepopping pitcher to the mounting surface.
 2. The popcorn popper of claim1, wherein the mounting surface is elevated above an interior floorsurface of the interior portion.
 3. The popcorn popper of claim 1,wherein the mounting surface includes a latch receiver for engaging thelatch member.
 4. The popcorn popper of claim 3, wherein the detachablepopping pitcher includes a pitcher handle.
 5. The popcorn popper ofclaim 4, wherein the pitcher handle includes a latch release that isinterconnected to the latch member, wherein biasing the latch releasecauses the latch member to disengage from the latch receiver.
 6. Thepopcorn popper of claim 1, wherein the detachable popping pitcherincludes an upper opening, and wherein the detachable popping pitcherincludes a kernel retention mechanism covering the upper opening.
 7. Thepopcorn popper of claim 6, wherein the kernel retention member includesone or more lid members hingedly covering the upper opening, and whereinthe one or more lid members is rotatable between a covering dispositionand an open disposition.